Part comprising an optimized steel material and its manufacturing process

ABSTRACT

The steel material has optimised, stable and isotropic mechanical properties, in particular so that the steel material can best withstand mechanical and/or thermal stresses.

TECHNICAL FIELD

The present invention pertains to the field of iron-based alloys, inparticular low carbon steels.

More particularly, the invention relates to an optimised steel material,the process for the manufacture or treatment of the steel material, aswell as to a part manufactured from the steel material and to theprocess for the manufacture of that part.

PRIOR ART

The standard NF E 67-001 defines additive manufacturing as “the set ofprocesses enabling a physical object, to be manufactured layer by layerby the addition of material, starting from a digital object.”.

Additive manufacture is a technology which can be used, to build partsby adding material, in contrast to “conventional” processes (machining,forging, rolling, etc) which are characterized by the removal ofmaterial (subtractive processes). It offers the possibility of designingparts with complex geometries which are impossible to produce withconventional processes. Because of the possibilities that they offerfrom a technical and economical point of view, additive manufacturingprocesses have been booming since the 1980s. These innovative processesfor shaping materials are used in various industrial sectors, inparticular in the medical, aeronautical and space fields.

The principle of additive manufacture (also known as “3D printing”) isthus that of a generative manufacturing process, which is basically twosteps which are reiterated until the finished solid product is obtained:

-   -   1. Generating a layer of material with a fixed contour and        thickness. The material is deposited only where it is required;    -   2. Producing a new layer by adding material above the preceding        layer. The manufacture can be summarised as being a “stepwise”        manufacture.

Among the many additive manufacturing processes, the selective lasermelting (SLM) process is one of the most widely known and used forbuilding metal parts.

A steel produced by an additive manufacturing process such as byselective laser melting, for example, has an austenitic face centredcubic structure.

Its microstructure is heterogeneous, but it is also hierarchical,depending on whether it is considered on a macro, micrometric ornanometric scale.

Thus, a microstructural anisotropy appears which is a function of theplane of observation: thus, two planes of observation (in the builddirection (//Z) and along the XY axis perpendicular to the builddirection (⊥Z)) are necessary in order to describe the microstructure ofthe steel produced by selective laser melting, as will be illustratedbelow.

Thus, this microstructure differs from that obtained by conventionalmanufacturing processes such as forging processes, which result in aforged steel.

Furthermore, when subjected to a high temperature, starting from 900°C., substantial microstructural modifications to the steel obtained byadditive manufacture occur. From this temperature, the cellularsub-structure is such that the cells of which it is composed grow largeruntil they disappear completely when the temperature is greater than950/1000° C. The grain size per se increases substantially from 1100° C.

Furthermore, a heat treatment (such as hot isostatic pressing, forexample (HIP)) causes significant microstructural modifications to thesteel produced by selective laser melting. By way of example, the grainsof the 316 L steels obtained are systematically equiaxial after a HIPtreatment at 1150° C. for 4 hours under a pressure of 1000 bar or 1150°C. for 3 hours at a pressure of 1500 bar; the equiaxial grains haveaverage sizes in the range 70 μm to 150 μm.

The microstructural anisotropy of a prior art steel material obtained byan additive manufacturing process is detrimental to the good behaviourof that material when it is subjected to thermal and/or mechanicalstresses. This anisotropy may be partially reduced after a heattreatment has been applied to the steel material, but this neverthelesssuffers from the disadvantage that it causes an increase in the grainsize of the steel material, which in turn is detrimental to itsresistance to thermal and/or mechanical stresses.

DISCLOSURE OF THE INVENTION

Thus, one of the aims of the invention is to prevent or mitigate one ormore of the disadvantages described above, in particular by providing asteel powder which is capable of forming a steel material withoptimised, stable and isotropic mechanical properties, in particular sothat the steel material is more resistant to mechanical and/or thermalstresses.

Thus, the present invention concerns a process for the manufacture of asteel material, in which a steel powder undergoes a consolidationprocess in order to form the material or undergoes a coating process inorder to coat a support with a coating comprising the material, thepowder being formed by particles which comprise a matrix into whichprecipitates are incorporated, the chemical composition of the powderbeing such that:

-   -   i) the powder comprises the following elements, as a percentage        by weight:        -   16% to 20% of chromium,        -   8% to 14% of nickel,        -   0.001% to 0.030% of carbon,        -   0.001% to 0.050% of oxygen,        -   0% to 2% of manganese,        -   0% to 3% of molybdenum,        -   0% to 1% of silicon,        -   the remainder of these elements being constituted by iron;    -   ii) the precipitates comprising at least one metallic element        selected from a metallic element M, a metallic element M′, a        metallic element M″ or mixtures thereof; the metallic elements        being selected independently of each other among yttrium,        titanium, iron, chromium, tungsten, silicon, zirconium, thorium,        magnesium, manganese, aluminium, hafnium, molybdenum or mixtures        thereof;    -   the microstructure of the steel being such that the grains are        equiaxial and the average size of the grains being such that the        average of their largest dimension “D max” and/or the average of        their smallest dimension “D min” is in the range 10 μm to 50 μm,        preferably 10 μm to 30 μm.

The inventors have identified a particular steel powder which, when itundergoes a consolidation process, results in a steel material withmicrostructural characteristics which are optimised for resistingmechanical and/or thermal stresses.

The steel powder may be obtained conventionally by gas atomisation undernitrogen or argon, but may also be obtained by water atomisation, inparticular if the powder is then treated by a selective laser melting(SLM) process.

The expression “the remainder of these elements” means that it is thesum of the explicitly mentioned chemical elements that makes up to atotal of 100% in the steel powder or in the steel material of theinvention. Thus, this does not exclude other chemical elements frombeing contained in the powder.

The elemental composition of the precipitates may be determined byenergy dispersive X-ray spectroscopy (known as EDX) carried out using aScanning Electron Microscope (SEM).

In general, the steel material obtained at the end of the manufacturingprocess of the invention is as defined in the present description, inparticular in accordance with one or more of the variations describedfor this material, such as the microstrueture and/or the composition ofthe material, for example. Unless mentioned otherwise, any of thecharacteristics of the precipitates or of the matrix contained in thesteel powder which undergoes the manufacturing process of the inventionis, for example, identical to the corresponding characteristics of theprecipitates or of the matrix contained in the steel material of theinvention, this characteristic being described in more detail in thedescription of the steel material. More particularly, unless mentionedotherwise, the size, the distribution of the precipitates in the matrix,or the chemical composition of the precipitates or of the matrix are notmodified between the steel powder and the steel material of theinvention.

Concerning the steel powder more particularly, the particles of thepowder may have a median diameter (d₅₀) in the range 10 μm to 200 μm.The median diameter (d₅₀) of a powder is the size for which 50% of thepopulation of the particles composing that powder has a size of lessthan d₅₀. It can be determined by means of a technique such as the laserdiffraction method, via a granulometer as described, for example, in thestandard ISO 13320 (2009 Dec. 1 edition).

The apparent density of the powder measured by the standard ASTM B-212may be in the range 3.5 g/cm³ to 4.5 g/cm³.

The true density of the powder may be in the range 7.95 g/cm³ to 8.05g/cm³. It is measured using a pycnometer, for example.

The consolidation process used in the manufacturing process of theinvention is an additive manufacturing process.

As indicated above, an additive manufacturing process comprises twosteps which are reiterated until a finished solid material is obtained:

1. Generating a layer of material with a fixed contour and thickness.

2. Producing a new layer by adding material above the preceding layer.

At the end of the additive manufacturing process, the successive layersof material forming the material are stacked in a directionperpendicular to the platen of the 3D printer onto which the first layerof material has been deposited.

Additive manufacturing is described in more detail, for example, in thefollowing documents which are hereby incorporated into the descriptionby reference:

-   -   F. Laverne et al., “Fabrication additive—Principes généraux”        [Additive manufacturing—General principles], Techniques de        l'ingénieur, Fascicule [Paper] BM7017 V2 (published 10 Feb.        2016).    -   H. Fayazfara et al., “Critical review of powder-based additive        manufacturing of ferrous alloys: Process parameters,        microstructure and mechanical properties”, Materials & Design,        Volume 144, 2018, pages 98-128.    -   T. DebRoy et al., “Additive manufacturing of metallic        components—Process, structure and properties”, Progress in        Materials Science, Volume 92, 2018, pages 112-224.    -   Ministère de l'économie et des finances, République Française        [French Ministry of Economic and Financial Affairs],        “Prospective—futur de la fabrication additive—rapport final”        [Prospective—the future of additive manufacturing—final report],        January 2017 edition, ISBN: 978-2-11-151552-9; in particular        Appendix 2 (pages 205 to 220), especially when it describes        additive manufacturing processes using a metallic powder        (Appendix 2, Les procédés de fabrication [Manufacturing        processes], paragraphs 3, 4 and 5).

More particularly, the additive manufacturing process may be selectedfrom a selective laser melting process, a selective electron beammelting process, a selective laser sintering process, a laser sprayingprocess or a binder spraying process.

The selective laser melting process (SLM) is carried out based on one ormore of the following parameters, for example:

-   -   the laser beam scans the steel powder at a scan speed in the        range 50 mm/second (dense material) to 3000 mm/second (porous        material);    -   power of laser beam: 50 W to 1000 W;    -   hatching distance: 25 μm to 150 μm;    -   layer thickness: 15 μm to 80 μm.

The electron beam melting process (EBM) is carried out based on one ormore of the following parameters, for example:

-   -   power of electron beam: 50 W to 4000 W;    -   speed of electron beam: 100 mm/s to 10000 mm/s;    -   hatching distance: 50 μm to 150 μm;    -   layer thickness: 40 μm to 75 μm.

The laser spraying process is carried out based on one or more of thefollowing parameters, for example:

-   -   power of laser: 400 W to 3 000 W;    -   rate of displacement of the nozzle: 150 mm/min to 1200 mm/min;    -   flow rate of powder: 4 g/min to 15 g/min.

The thermal spraying process is selected, for example, from a flamespraying process, a two-wire electric arc spraying process or a plasmajet spraying process.

At the end of the manufacturing process of the invention in which thesteel powder is subjected to a consolidation process, the material is,more particularly, in the solid form.

When the consolidation process is carried out in a mould, a solid partconstituted by the material is obtained.

The present invention also concerns the steel material obtained orcapable of being obtained by the manufacturing process of the invention.

The present invention also concerns a steel material wherein the grainsof which it is composed comprise a matrix into which precipitates areincorporated, in which material:

-   -   i) the material comprises the following elements, as a        percentage by weight:        -   16% to 20% of chromium,        -   8% to 14% of nickel,        -   0.001% to 0.030% of carbon,        -   0.001% (preferably 0.030%) to 0.050% of oxygen,        -   0% to 2% of manganese,        -   0% to 3% of molybdenum,        -   0% to 1% of silicon,        -   the remainder of these elements being constituted by iron;    -   ii) the precipitates comprising at least one metallic element        selected from a metallic element M, a metallic element M′, a        metallic element M″ or mixtures thereof; the metallic elements        being selected independently of each other among yttrium,        titanium, iron, chromium, tungsten, silicon, zirconium, thorium,        magnesium, manganese, aluminium, hafnium, molybdenum or mixtures        thereof;    -   the microstructure of the steel being such that the grains are        equiaxial and the average size of the grains being such that the        average of their largest dimension “D max” and/or the average of        their smallest dimension “D min” is in the range 10 μm to 50 μm,        preferably in the range 10 μm to 30 μm (or even optionally in        the range 15 μm to 25 μm).

The average grain size of the material is measured by the interceptmethod as described, for example, in:

-   -   “https://en.wikipedia.org/wiki/Intercept_method”,    -   the standard ASTM E112-10 described, for example, in the        document        “fushunspecialsteel.com/wp-content/uploads/2015/09/ASTM-E112-2010-Standard-Test-Methods-for-Determining-Average-Grain-Size.pdf”.

The grains may be equiaxial in a plane which is parallel to the plane ofthe superimposed layer's of material which result from the manufactureof material by an additive manufacturing process. In addition to theparallel plane, the grains may also be equiaxial in a plane which isperpendicular to the plane of the superimposed layers of material whichresult from the manufacture of material by an additive manufacturingprocess.

The interface between these superimposed layers, and thus the directionof these layers is generally visible by Scanning Electron Microscopy(SEM) or by optical microscopy.

Preferably, the equiaxial grains are such that the average ratio D max/Dmin between the largest dimension “D max” and the smallest dimension “Dmin” of a grain is in the range 1 to 2 (more particularly in the range 1to 1.5).

The average ratio D max/D min is, for example, calculated by taking theaverage of the ratio D max/D min over at least 10 (or even at least 50)grains observed by Scanning Electron Microscope (SEM) imaging.

The material may have a relative density in the range 70.0% to 99.9%.The relative density can be used to ascertain the porosity of amaterial. It is measured using the Method of Archimedes, for example.

Concerning the composition of the precipitates contained in the steelmaterial of the invention or in the steel powder used in themanufacturing process of the invention, the precipitates may comprise atleast one metallic oxide, at least one metallic carbide, at least oneoxymetallic carbide, at least one intermetallic compound, or mixturesthereof. Each of these oxide, carbide, oxycarbide or intermetalliccompounds comprises at least one metallic element selected from metallicelement M, metallic element M′, metallic element M″ or mixtures thereof;more particularly comprising metallic element M (more particularlytitanium, iron, chromium or mixtures thereof), optionally metallicelement M′ optionally with metallic element M″, or the mixture of thesemetallic elements.

The material of the invention or the steel powder used in themanufacturing process of the invention may comprise 0% to 1.5% by weightof metallic oxide (more particularly 0.1% to 1.5%).

The metallic oxide contained in the precipitates of the steel materialof the invention or in the steel powder used in the manufacturingprocess of the invention is selected from at least one simple oxide, atleast one mixed oxide or mixtures thereof.

More particularly, the metallic oxide is selected from at least onesimple oxide MO_(2-x) with the index X in the range 0 to 1, at least onemixed oxide MM′_(y′)O_(5-x′) with the index X′, which differs from 5,being in the range 0 to 5 and the index y′, which is non-zero, being inthe range 0 to 2, or at least one mixed oxide MM′_(y′)M″_(y″)O_(5-x″)with the index X″, which differs from 5, being in the range 0 to 5, theindex y′, which is non-zero, being in the range 0 to 2 and the index y″in the range 0 to 2, or mixtures of these oxides.

As an example, the index “x” is as follows for different compounds:

-   -   X=0: TiO₂    -   X=1: FeO    -   X=0.5: Fe₂O₃    -   X=2/3: Fe₃O₄

The index “y′” is, for example, equal to 0, 1 or 2.

The metallic element M contained in the simple oxide MO_(2-x), the mixedoxide MM′_(y′)O_(5-x′) or the mixed oxide MM′_(y′)M″_(y″)O_(5-x″) ismore particularly selected from yttrium, iron, chromium, titanium,aluminium, hafnium, silicon, zirconium, thorium, magnesium or manganese.

The metallic element M contained in the metallic oxide (in particularthe simple oxide MO_(2-x)) is more particularly selected from titanium,iron or chromium.

The simple oxide MO_(2-x) is, for example, selected from Y₂O₃, Fe₂O₃,FeO, Fe₃O₄, Cr₂O₃, TiO₂, Al₂O₃, HfO₂, SiO₂, ZrO₂, ThO₂, MgO, MnO, MnO₂or mixtures thereof. More particularly, the simple oxide is TiO₂.

The metallic element M contained in the mixed oxide MM′_(y′)O_(5-x′) isselected from iron or yttrium, for example.

The metallic element M′ contained in the mixed oxide MM′_(y′)O_(5-x′) orthe mixed oxide MM′_(y′)M″_(y″)O_(5-x″) is more particularly selectedfrom titanium or yttrium.

The mixed oxide MM′_(y′)O_(5-x′) is selected from FeTiO₃, Y₂Ti₂O₇,YTi₂O₅ or mixtures thereof, for example. More particularly, the mixedoxide is TiYO_(5-x′).

The mixed oxide MM′_(y′)O_(5-x′) may be a pyrochlore, for exampleY₂Ti₂O₇ or YTi₂O₅, or a mixture thereof.

The mixed oxide MM′_(y′)M″_(y″)O_(5-x″) is, for example, of the“SiOAlMn” general formula type, denoted without any stoichiometricindices.

The precipitates contained in the steel material of the invention or inthe steel powder used in the manufacturing process of the invention mayalso comprise at least one metallic carbide selected, for example, fromat least one simple carbide or a mixed carbide.

More particularly, the metallic carbide is selected, for example, fromat least one simple carbide MC_(8-x) with the index X, which differsfrom 8, being in the range 0 to 8, at least one mixed carbideMM′_(y′)C_(8-x′) with the index X′, which differs from 8, being in therange 0 to 8 and the index y′ in the range 0 to 5, or mixtures of thesecarbides.

The material or the steel powder used in the manufacturing process ofthe invention may comprise 0% to 0.9% (or even 0.1% to 0.9%) by weightof metallic carbide.

The metallic element M contained in the simple carbide MC_(8-x) or themixed carbide MM′_(y′)C_(8-x′) is, for example, selected from iron,titanium, chromium, aluminium, tungsten or silicon.

The simple carbide MC_(8-x) is, for example, selected from TiC, SiC,AlC₃, CrC or mixtures thereof.

The metallic element M′ contained in the mixed carbide MM′_(y′)C_(8-x′)is, for example, selected from iron, titanium, chromium, aluminium,tungsten or silicon.

The mixed carbide MM′_(y′)C_(8-x′) is, for example, selected from(FeCr)₇C₃ or (FeCr)₂₃C₆.

The precipitates contained in the steel material of the invention or inthe steel powder used in the manufacturing process of the invention maycomprise at least one oxymetallic carbide comprising metallic element M,metallic element M′, metallic element M″ or mixtures thereof.

The material or the steel powder used in a manufacturing process of theinvention may comprise 0% to 1.5% by weight of oxymetallic carbide (moreparticularly 0.1% to 1.5%).

The metallic oxide and the metallic carbide may coexist in theprecipitates of the material or the steel powder used in themanufacturing process of the invention. The oxymetallic carbide whichmay result from this may more particularly comprise a metallic oxide anda metallic carbide which have a composition as defined above.

More particularly, the precipitates of carbide and/or of oxycarbide maybe localised at the boundaries of the grains forming the particles ofsteel powder or at the boundaries of the grains of which the steelmaterial is composed, these precipitates having an average size in therange 10 nm to 100 nm, or even in the range 10 nm to 50 nm.

The precipitates contained in the steel material of the invention or inthe steel powder used in the manufacturing process of the invention mayalso comprise at least one intermetallic compound comprising metallicelement M, metallic element M′ or even, optionally, metallic element M″.

The material or the steel powder used in the manufacturing process ofthe invention may comprise 0% to 2% by weight of intermetallic compound(more particularly 0.1% to 1.5%).

The metallic element M contained in the intermetallic compound is iron,for example.

The metallic element M′ contained in the intermetallic compound istitanium or yttrium, for example.

The metallic element M″ contained in the intermetallic compound ischromium or tungsten, for example.

The intermetallic compound is, for example, selected from YFe₃, Fe₂Ti,FeCrWTi or mixtures thereof. FeCrWTi is a term which is known to theperson skilled in the art, but it does not correspond to a truestoichiometric formula.

The precipitates incorporated into the matrix may also have thefollowing characteristics for the steel material of the invention or thesteel powder used in the manufacturing process of the invention.

The precipitates contained in the steel material or in the steel powderused in the manufacturing process of the invention may have an averagesize in the range 5 nm to 200 nm, preferably in the range 5 nm to 100nm, yet more preferably in the range 5 nm to 70 nm.

The average size of the precipitates may be determined visually startingfrom a measurement made on an image obtained with a Scanning ElectronMicroscope (SEM), for subsequent processing with image processingsoftware such as “ImageJ” software, for example, which is available fromthe following web site: https://imagej.net/Welcome.

The precipitates of metallic carbide may have an average size in therange 10 nm to 50 nm.

The precipitates of metallic oxide and/or of oxymetallic carbide mayhave an average size in the range 10 nm to 100 nm, more particularly inthe range 20 nm to 70 nm.

The steel material of the invention or the steel powder used in themanufacturing process of the invention may comprise 0.1% to 1.5% byweight of precipitates. This precipitates content may, for example, bemeasured by selective dissolution with aqua regia.

The average density with which the precipitates are distributed in thematrix may be in the range 2 precipitates/μm³ to 100 precipitates/μm³.

It is determined by counting from images, for example, such as fromScanning Electron Microscopic (SEM) imaging, or from TransmissionElectron Microscopy (TEM) imaging, for example.

In addition to the chemical elements cited above, the material or thesteel powder used in the manufacturing process of the invention maycomprise at least one of the following elements, as a percentage byweight:

-   -   0% to 0.11% of nitrogen,    -   0% to 0.045% of phosphorus,    -   0% to 0.05% of sulphur,    -   0% to 0.0300% of aluminium,    -   0% to 2% of manganese,    -   0% to 3% of molybdenum,    -   0% to 0.003% of vanadium.

In addition to the chemical elements cited above, notably at thepreceding paragraph, the material or the steel powder used in themanufacturing process of the invention may still comprise at least oneof the following elements, as a percentage by weight:

-   -   0% to 0.02% of cobalt,    -   0% to 0.02% of titanium,    -   0% to 0.02% of copper.

These supplemental chemical elements may be present in the matrix and/orin the precipitates.

The matrix may comprise, as a proportion by weight with respect to theweight of the material or with respect to the weight of the steel powderused in the manufacturing process of the invention, 0 ppm to 500 ppm ofmetallic element M, of metallic element M′ and/or of metallic elementM″. In this case, it is the metallic element which is dissolved in thematrix, in contrast to that present in the precipitates.

More particularly, the metallic element M, M′ or M″ contained in thematrix may be selected from yttrium, titanium, tungsten, zirconium,thorium, aluminium, hafnium, silicon, manganese or molybdenum.

The material or the steel powder used in the manufacturing process ofthe invention may have an austenitic structure.

The matrix (and thus by extension the steel material of the invention orthe steel powder used in the manufacturing process of the invention) mayhave the chemical composition of a 316 L or 304 L type steel, forexample as respectively specified in the standards ASTM A666 or RCC-MRx.

The microstructure of the material may be such that the grains of whichit is composed have a cellular structure. This cellular sub-structureis, for example, illustrated in the document “Techniques del'ingénieur-fascicule [paper] M140v3: Mécanismes de fluage. Effet de lamicrostructure du matériau Essais de fluage [Creep mechanisms. Effectsof the microstructure of the material. Creep tests]. Author(s): FrançoisSAINT-ANTONIN—publication date: 10 Jul. 1995”.

The grains with a cellular structure are, for example, composed of cellswith an average size in the range 300 nm to 2 μm.

Regarding the mechanical properties of the steel material of theinvention, they generally have at least, one of the following values:

-   -   elongation at break “A” of 35% to 85%, and/or    -   “Rp0.2” yield strength of 190 MPa to 700 MPa, and/or    -   maximum tensile strength “Rm” of 400 MPa to 900 MPa.

The present invention also concerns a treatment process in which a steelmaterial undergoes hot isostatic pressing, the material being such thatthe grains of which it is composed comprise a matrix into whichprecipitates are incorporated and such that:

-   -   i) the material comprises the following elements, as a        percentage by weight:        -   16% to 20% of chromium,        -   8% to 14% of nickel,        -   0.001% to 0.030% of carbon,        -   0.001% to 0.050% of oxygen,        -   0% to 2% of manganese,        -   0% to 3% of molybdenum,        -   0% to 1% of silicon,        -   the remainder of these elements being constituted by iron;    -   ii) the precipitates comprising at least one metallic element        selected from a metallic element M, a metallic element M′, a        metallic element M″ or mixtures thereof; the metallic elements        being selected independently of each other among yttrium,        titanium, iron, chromium, tungsten, silicon, zirconium, thorium,        magnesium, manganese, aluminium, hafnium, molybdenum or mixtures        thereof;        -   the microstructure of the steel being such that the grains            are equiaxial and the average size of the grains being such            that the average of their largest dimension “D max” and/or            the average of their smallest dimension “D min” is in the            range 10 μm to 50 μm.

The hot isostatic pressing may comprise the following steps insuccession, carried out in a chamber comprising an inert gaseousatmosphere under a pressure in the range 120 bar to 1800 bar:

-   -   a) the material is heated to a constant temperature in the range        600° C. to 1400° C. at a temperature ramp-up rate in the range        500° C./hour to 1000° C./hour;    -   b) the constant temperature is maintained for a period in the        range 15 minutes to 5 hours;    -   c) the constant temperature is reduced at a temperature        ramp-down rate in the range 500° C./hour to 1000° C./hour in        order to reach ambient temperature.

The ambient temperature is typically 25° C.

The inert gaseous atmosphere (i.e., chemically inert in respect of thematerial as at the start and end of the treatment process) may comprisea gas selected, for example, from argon, helium or a mixture thereof.

In general, the steel material which undergoes the treatment, of themanufacturing process of the invention is as defined in the presentdescription, in particular in accordance with one or more of thevariations described for this material in respect of the microstructureand/or the composition of the material, for example.

The present invention also concerns a part composed entirely or in partof a steel material, the grains of which it is composed comprising amatrix into which precipitates are incorporated and such that:

-   -   i) the material comprises the following elements, as a        percentage by weight:        -   16% to 20% of chromium,        -   8% to 14% of nickel,        -   0.001% to 0.030% of carbon,        -   0.001% to 0.050% of oxygen,        -   0% to 2% of manganese,        -   0% to 3% of molybdenum,        -   0% to 1% of silicon,        -   the remainder of these elements being constituted by iron;    -   ii) the precipitates comprising at least one metallic element        selected from a metallic element M, a metallic element M′, a        metallic element M″ or mixtures thereof; the metallic elements        being selected independently of each other among yttrium,        titanium, iron, chromium, tungsten, silicon, zirconium, thorium,        magnesium, manganese, aluminium, hafnium, molybdenum or mixtures        thereof;    -   the microstructure of the steel being such that the grains are        equiaxial and the average size of the grains being such that the        average of their largest dimension “D max” and/or the average of        their smallest dimension “D min” is in the range 10 μm to 50 μm.

The part may have a cellular structure or an alveolar structure asdescribed, in particular, in the document FR 2 932 705 A1 (in particularthe parts illustrated in FIGS. 1 to 14 and as commented upon in thedescription of that document) and/or the dissertation “Développementd'une nouvelle technique d'élaboration de mousses acier par fonderie etcaractérisation mécanique” [Development of a novel technique formanufacturing steel foams by smelting and mechanical characterization]by Jonathan Dairon (in particular pages 109 to 112), available from thefollowing address:https://tel.archives-ouvertes.fr/tel-00694478/document.

More particularly, the part has a honeycomb structure, a latticestructure or a foam structure.

The largest dimension of the cell or of the alveolus respectivelyforming the cellular structure or the alveolar structure may be in therange 1 nm to 1 cm or in the range 5 cm to 10 cm.

The part may be a shock absorber.

In general, the steel material which composes all or a portion of thepart of the invention is as defined in the present description, inparticular in accordance with one or more of the variations describedfor this material such as, for example, the microstructure and/or thecomposition of the material.

The present invention also concerns a process for the manufacture of apart as defined in the present description, in particular in accordancewith one or more of the variations described for this part such as, forexample, the structure (in particular the cellular or alveolarstructure, particularly a honeycomb structure, a lattice structure or afoam structure) and/or the composition of the material, or even of thematerial obtained after the treatment process of the invention.

The process for the manufacture of a part in accordance with theinvention is such that the part is manufactured by means of an additivemanufacturing process.

More particularly, the additive manufacturing process is selected from aselective laser melting process, a selective electron beam meltingprocess, a selective laser sintering process, a laser spraying processor a binder spraying process.

The process for the manufacture of the part may be followed by atreatment process comprising a step for hot isostatic pressing.

This step for hot isostatic pressing may comprise the following steps insuccession, carried out in a chamber comprising an inert gaseousatmosphere under a pressure in the range 120 bar to 1800 bar:

-   -   A. the material is heated to a constant temperature in the range        600° C. to 1400° C. using a temperature ramp-up rate in the        range 500° C./hour to 1000° C./hour;    -   B. the constant temperature is maintained for a period in the        range 15 minutes to 5 hours;    -   C. the constant temperature is reduced at a temperature        ramp-down rate in the range 500° C./hour to 1000° C./hour in        order to reach ambient temperature.

The inert gaseous atmosphere may comprise a gas selected from argon,helium or a mixture thereof.

The invention is advantageously complemented by the followingcharacteristics, taken alone or in accordance with any one of theirtechnically feasible combinations.

DETAILED DISCLOSURE OF THE INVENTION

In the present description of the invention, a verb such as “comprise”,“incorporate”, “include”, “contain” and its conjugated forms are openterms and thus do not exclude the presence of additional element(s)and/or step(s) adding to the initial element(s) and/or steps mentionedafter these terms. However, these open terms also encompass a particularembodiment in which only the initial element(s) and/or step(s), to theexclusion of any others, are envisaged; in which case, the open termalso encompasses the closed term “consist of”, “constitute”, “composeof” and its conjugated forms.

Unless indicated otherwise, the use of the indefinite article “a” or“an” for an element or a step does not exclude the presence of aplurality of elements or steps.

Any reference symbol between parentheses in the claims should not beinterpreted as limiting the scope of the invention.

Furthermore, unless indicated otherwise:

-   -   limiting values are included in the indicated ranges of        parameters (except, for example, in the case of the explicit        exclusion of the value of a limit);    -   unless the margin of error is indicated, the degrees of        uncertainty for the values mentioned are such that the maximum        error for the last figure indicated must be estimated from        rounding conventions. As an example, for a measurement of 3.5,        the margin of error is 3.45-3.54;    -   the temperatures indicated are considered for an implementation        at atmosphere pressure;    -   all percentages by weight for a powder or for a material are        with respect, to the total weight, of that powder or that        material;    -   the indices mentioned in the formulae for the metallic        precipitates (oxides, carbides, oxycarbides and intermetallic        compounds) are stoichiometric indices and not indices by weight,        as is sometimes the case in metallurgy.

The expression “in accordance with one or more of the variationsdescribed in the present description” for a material (in particular thesteel material of the invention or the steel powder used in themanufacturing process of the invention) or an element, refers inparticular to the variations which concern the chemical compositionand/or the proportion of the constituents of that material and anysupplemental chemical species which it might possibly contain and inparticular to variations which concern the chemical composition,structure, geometry, arrangement in space and/or chemical composition ofthat element or of a constituent sub-element of the element. Thesevariations are, for example, those that are indicated in the claims.

Other aims, characteristics and advantages of the invention will now bedescribed in detail in the description below of particular embodimentsof the invention, given by way of non-limiting illustration, withreference to the accompanying FIGS. 1 to 20.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 represents a table indicating ranges of overall contents byweight for the chemical elements composing the steel powder of theinvention as well as, by way of comparison, corresponding contents asdefined in the standards ASTM A666 and RCC-MRx.

FIG. 2 represents a table detailing the content by weight and the atomiccontent of the chemical in the matrix and in the precipitates of a steelpowder in accordance with the invention.

FIG. 3 represents a table indicating the content by weight of thechemical elements in the steel material of the invention, in the matrix,the oxide precipitates, the carbide precipitates and the oxycarbideprecipitates.

FIG. 4 and

FIGS. 4 and 5 represent images obtained by Electron BackscatteredDiffraction of a steel material of the invention, respectively in aplane parallel to and in a plane perpendicular to the direction z ofadditive manufacture of the material.

FIG. 6 is a pole figure for the steel material of the invention obtainedfrom data collected by Electron Backscattered Diffraction (EBSD).

FIG. 7 is an image obtained by Scanning Electron Microscopy (SEM)showing the cells present inside the steel material of the invention.

FIG. 8 is a micrograph obtained by Transmission Electron Microscopy(MET) of a thin slice of the steel material of the invention.

FIG. 9 and

FIGS. 9 and 10 represent images obtained by Electron BackscatteredDiffraction of a steel material which has undergone the treatmentprocess of the invention, respectively in a plane parallel to and aplane perpendicular to the direction z of additive manufacture of thematerial.

FIG. 11 is a pole figure for steel material which has undergone thetreatment process of the invention, obtained from data collected byEBSD.

FIG. 12 represents a graph expressing the misorientation angle expressedin degrees as a function of the frequency, expressed as a %, for thesteel material of the invention before (“unrefined”) and after havingundergone the treatment, process of the invention (“HIP”).

FIG. 13 represents a table indicating the overall content by weight ofthe chemical elements of a reference steel powder.

FIG. 14 represents a table indicating the content by weight of thechemical elements composing the matrix and the precipitates of areference steel powder.

FIG. 15 and

FIGS. 15 and 16 represent images obtained by Electron BackscatteredDiffraction of a reference steel material respectively in a planeparallel to and in a plane perpendicular to the direction z of additivemanufacture of the material.

FIG. 17 represents a table indicating the content by weight of thechemical elements composing a reference steel material.

FIG. 18 represents a pole figure for a reference steel material obtainedfrom data collected by EBSD.

FIG. 19 represents un graph indicating, for a reference steel materialand for a steel material of the invention (unrefined materials andmaterials after treatment (s)): on the one hand, up the left hand sideordinate is the average size of the grains, expressed in μm for thelargest dimension and the smallest dimension of the grains, and on theother hand, up the right hand side ordinate is the ratio between thesetwo dimensions.

FIG. 20 represents a table indicating the mechanical properties of thesteel material of the invention and of a reference steel material (in adirection parallel to and perpendicular to the direction z of additivemanufacture of the material), as well as the anisotropy of theseproperties.

DESCRIPTION OF PARTICULAR EMBODIMENTS 1. Steel Powder Used in theManufacturing Process of the Invention

In general, the steel powder had a composition as shown in FIG. 1,namely a composition by weight encompassing that of a steel complyingwith the ASTM A666 and RCC-MRx standards (the RCC-MRx standardcorresponds to the rules for the design and construction of mechanicalequipment for high temperature, experimental and fusion nuclearfacilities. It is a technical document for the production of componentsfor Generation IV nuclear reactors).

1.1 Characterization of Steel Powder.

1.1.1 Chemical Composition.

A steel powder (316 L steel with reference FE-271-3/TruForm 316-3—batchno. 12-034043-10, sold by Praxair) was analysed by X ray microanalysis,more precisely by Energy Dispersive X-ray Spectroscopy (EDX) using aScanning Electron Microscope (SEM)), as well as by Glow Discharge MassSpectrometry (GDMS), by Inductively Coupled Plasma—Optical EmissionSpectrometry (ICP-OES) and by Instrumental Gas Analysis (IGA).

The elemental composition of the matrix and of the precipitates of thesteel powder obtained was determined by compiling these variousmeasurements. The proportions obtained for each chemical element, areexpressed with a relative uncertainty of 3%:

-   -   as a % by weight with respect to the total weight of the matrix.        However, by convention, the unmeasured chemical elements are        subtracted for the matrix. It was then assumed that the        remaining percentage by weight was constituted by iron.    -   as a % by weight and as an atomic % with respect to the total        weight of precipitates contained in the steel powder.

These proportions were normalised by assigning a value of 100 to thetotal weight or the total number of atoms. They are reproduced in FIG.2, which shows that the precipitates are rich in oxides of aluminium,titanium, silicon and manganese in the form of a simple oxide and/ormixed oxide. The precipitates may optionally contain carbides oroxycarbides of these chemical elements which, however, would not havebeen detected by SEM because of their small size.

1.1.2 Morphology.

The steel powder had a 100% austenitic structure, as shown by anElectron Backscattered Diffraction (“EBSD”) analysis.

The particles of this powder comprise grains agglomerated into particleswhich are most usually substantially spherical. They have a diameter inthe range 10 μm to 100 μm, and an average diameter of 34 μm. Moreparticularly, the median diameters D₁₀, D₅₀ and D₉₀ (for which,respectively, 10%, 50% and 90% of the population of the particlescomposing this powder had a size which was below the median diameterunder consideration) measured by laser granulometry in accordance withthe standard ISO 13320 (2009 Dec. 1 edition) were as follows: D₁₀=22 μm,D₅₀=32 μm, and D₉₀=48 μm.

The precipitates contained in the particles of the powder are most oftenspherical. Their maximum dimensions (which therefore most oftencorrespond to the diameter of the spherical particle) were such that thesize measured by Scanning Electron Microscope (SEM) imaging wasgenerally in the range 24 nm to 120 nm. Their corresponding average sizewas 63 nm.

The density with which the precipitates were distributed in the matrixwas measured by counting using SEM imaging: it was in the range 2precipitates/μm³ to 100 precipitates/μm³. The corresponding averagedensity was 6 precipitates/μm³.

1.1.3 Properties.

The apparent density of the steel powder, measured by the standard ASTMB-212, was 4 g/cm³±0.01 g/cm³. Its true density, measured by heliumpycnometry, was 7.99 g/cm³±0.03 g/cm³.

The Hall flow rate (capacity to make 50 g of powder flow through anorifice of fixed dimensions), measured in accordance with the standardASTM B213, was more than 40 seconds.

2. Manufacturing Process in Accordance with the Invention

A part composed of a steel material in accordance with the invention wasmanufactured by additive manufacture with the Selective Laser Melting(SLM) process using a Trumpf TruPrint Series 1000 model printer.

In order to manufacture the part, on a substrate of stainless steel, thelaser scanned a plurality of 4 mm sided squares in succession,distinguished by a scan direction perpendicular to that of the precedinglayer. At the end of this first scan, a first layer n in the form of acheckerboard was obtained. After a second scan carried out on the layern in which a fresh rotation by 90° of the laser scan direction had beencarried out, a new layer n+1 was superimposed on the subjacent layer n.

The principal operating parameters of the SLM process were as follows:

-   -   Yb fibre laser with wavelength of 1.064 nm;    -   diameter of spot laser=55 μm;    -   power of laser=150 W;    -   scan speed of laser=675 mm/s;    -   distance between two successive laser tracks (“Hatching        distance”)=90 μm;    -   thickness of bed of powder=20 μm;    -   composition of gaseous medium of the build chamber=argon, with        an oxygen content of less than 100 ppm during consolidation.

Five cylindrical specimens (length=40 mm and diameter=8 cm) built withaxes X and Z and five parallelepipedal specimens (10 mm×10 mm×15 mm)were obtained. After manufacture, the parts were removed by cuttingspecimens from the base in order to separate them from the stainlesssteel substrate.

The cylindrical specimens were then machined for the tensile tests. Theparallelepipedal specimens were used for all of the composition andmicrostructure analyses.

No supplemental treatments were applied to the unrefined materialobtained.

The density of the steel material constituting the specimens was 7.93g/cm³ (measured using the Method of Archimedes), i.e. a relative densityof 99.25%, assuming that the theoretical density for a 316 L steel is7.99 g/cm³.

This density could be increased by modifying at least one of thefollowing parameters until a relative density of more than 99% wasreached without, however, modifying the grain size of the steelmaterial:

-   -   power of laser=50 W to 400 W;    -   scan speed of laser=50 mm/s to 3000 mm/s.

The density generally varies with the power of the laser or the scanspeed of the laser in a parabolic manner. However, too low or too high apower or scan speed could possibly reduce the density.

The distance between two successive laser tracks (“Hatching distance”)was in the range 30 μm to 90 μm, for example.

3. Characterization of the Steel Material Obtained by the ManufacturingProcess in Accordance with the Invention

3.1.1 Chemical Composition.

The overall chemical composition of the steel material obtained by themanufacturing process described in the preceding example complied withthe standards ASTM A666 and RCC-MRx indicated in the table of FIG. 1.

The elemental composition of this alloy was measured by EDX analysis. Itwas very similar to that of the steel powder used to manufacture thesteel material. However, in the steel material, the chemical elementsare distributed differently between the matrix and the oxide, carbide oroxycarbide precipitates (namely, for example, a mixture of oxide andcarbide): their percentages by weight, measured locally on one or moreof these precipitates, are indicated in the table of FIG. 3 with arelative uncertainty of 3%.

This table shows that the metallic oxides (in the form of a simple oxideand/or mixed oxide) are rich in chromium, iron and nickel in particular,but also in aluminium, titanium, silicon or manganese. The carbides (inthe form of simple carbides and/or of mixed carbides) are rich in ironor chromium in particular, and silicon or manganese to a lesser extent.The oxycarbides are in fact rich in chromium, manganese, iron, andsilicon, titanium and nickel to a lesser extent.

3.1.2 Morphology.

An analysis by Electron Backscattered Diffraction (“EBSD”) showed thatthe steel material has a 100% austenitic structure.

The oxide, carbide and oxycarbide precipitates were incorporated intothe matrix of the grains which constituted the steel material or intothe spaces between these grains (grain boundaries). The average densitywith which these precipitates were distributed in the matrix was 6precipitates/μm³.

The average size of the oxide precipitates was in the range 10 nm to 100nm; that for carbide was in the range 10 nm to 50 nm; that for theoxycarbide precipitates was in the range 10 nm to 100 nm.

One of the particular features of the material of the invention is amicrostructure such that the grains comprising this material areequiaxial in structure. In particular, when the material of theinvention is obtained by additive manufacture, its grains may beequiaxial in a plane parallel to the direction of additive manufacture(which in general corresponds to a plane which is substantiallyperpendicular to the direction of the layers successively obtainedduring manufacture).

This particular microstruetural feature of the material of the inventionis illustrated in FIGS. 4 and 5, which show the equiaxial structure ofthe grains in a plane respectively parallel to and a plane perpendicularto the direction z of additive manufacture of the steel material. Thesegrains had an average width (D min) of 16.2 μm±1.5 μm and an averagelength (D max) of 20.6 μm±1.5 μm, i.e. an average ratio D max/D min of1.34±0.13.

Furthermore, the crystallites which form the grains of the steelmaterial have a preferential orientation. As illustrated in FIG. 6, thistexture of the material is reflected by the fact that the (110)directions are preferentially orientated parallel to the build directionZ, but also by a texture intensity equal to 1.9.

As illustrated in FIG. 7, the grains of steel material are themselvesconstituted by cells which are nanometric in scale (more particularly asize of less than the average diameter of 500 nm).

FIG. 8 also illustrates this cellular structure while also highlightingthe precipitates incorporated into the matrix, which itself is paler incolour.

3.1.3 Properties.

The mechanical properties of the steel material are as follows:

-   -   Vickers HV1 microhardness (1 kg for 10 seconds):        -   202±3 HV1 in the plane parallel to the direction Z of            manufacture and 202±3 HV1 in the plane perpendicular to the            direction Z of manufacture;    -   tensile tests at ambient temperature (25° C.) and irrespective        of the direction of measurement with reference to the direction        Z of manufacture:        -   Rm (maximum tensile strength)=645±30 MPa;        -   Rp0.2 (yield strength)=453±35 MPa;        -   A (elongation at break)=54±9%.

Thus, advantageously, the steel material obtained directly from themanufacturing process of the invention (namely the unrefined materialwhich has not undergone any supplemental treatment such as a heattreatment, for example) has optimised mechanical properties which are,furthermore, homogeneous in all directions (isotropic nature of theseproperties).

4. Treatment Process in Accordance with the Invention

The steel material manufactured in accordance with the preceding exampleunderwent the treatment process of the invention comprising a step forhot isostatic pressing (HIP).

This HIP consisted of heating the material, under an atmosphere of argonat a pressure of 1800 bar, from ambient temperature (25° C.) to aconstant temperature of 1100° C. which was maintained for 3 hours, andthen returning it to ambient temperature. The temperature ramp-up orramp-down rate was 800° C./hour.

As an alternative, the constant temperature could have been in the range600° C. to 1400° C.

5. Characterization of Steel Material Obtained by the Treatment Processin Accordance with the Invention

5.1.1 Morphology.

The treated material no longer had a cellular structure.

In contrast, phase mapping by Electron Backscattered Diffraction(“EBSD”) showed that the treated material still had a 100% austeniticstructure, as well as equiaxial grains, as illustrated in FIGS. 9 and10, which show the equiaxial structure of the grains in a planerespectively parallel to and perpendicular to the direction z ofadditive manufacture of the steel material undergoing the treatmentprocess of the invention.

These grains had an average width of 15.9 μm±2.2 μm and an averagelength of 21.5 μm±1.2 μm, i.e. an average ratio D max/D min of1.36±0.16.

As illustrated in FIG. 11, the treated material was still structured,since the (110) directions are preferentially orientated parallel to thebuild direction Z.

The misorientation angle between two grain boundaries was measured usingthe pole figure technique. In theory, after a treatment by hot isostaticpressing, the grains of a steel material are assumed to increase in sizeand/or in number. This change then modifies the distribution of themisorientation angles.

However, FIG. 12 shows that the misorientation angle between the grainsdid not vary significantly after the steel material had been treated bythe treatment process of the invention. This provides evidence of anabsence of modification to the size of the grains.

Apart from the cellular structure, these various data show that themorphology of the steel material is advantageously stable (in particularthe variation in the size of the grains is minor), even after havingundergone the treatment process of the invention which, however,combines the application of variations in temperature and in pressure.

This stability in the morphology of the steel material of the inventionis advantageous, for example when its creep behaviour is considered whena pressure and/or temperature stress is applied to the material.

5.1.2 Properties.

The mechanical properties of the steel material which has undergone thetreatment process of the invention are as follows:

-   -   Vickers HV1 microhardness (1 kg for 10 seconds):

175±1.5 HV1 in the plane parallel to the direction Z of manufacture and172±2 HV1 in the plane perpendicular to the direction Z of manufacture:the microhardness with respect to the untreated material was thusreduced, but was advantageously isotropic;

-   -   tensile tests at ambient temperature (25° C.) and irrespective        of the direction of measurement with respect to the direction Z        of manufacture:    -   Rm (maximum tensile strength)=622±22 MPa;    -   Rp0.2 (yield strength)=336±8 MPa;    -   A (elongation at break)=76±4%.

These various mechanical properties are advantageously isotropic, namelyirrespective of the direction in which they are measured. The isotropictensile behaviour of the steel material of the invention is relativelystable over time.

The density of the treated steel material constituting specimens with ageometry similar to those of the unrefined steel material was 7.94g/cm³±0.05 g/cm³ (measured using the Method of Archimedes), i.e. arelative density of 99.4%±0.06%, assuming that the theoretical densityfor a 316 L steel is 7.99 g/cm³.

The density of the steel material which had undergone the treatmentprocess of the invention was thus almost identical to that of thecorresponding unrefined material.

6. Comparative Example

By way of comparison, a reference steel powder (Stainless Steel 316L-ALMF powder—batch no. 201600024, sold by Trumpf) underwent an additivemanufacturing process in accordance with the operating parameters ofExample 2, in order to obtain a solid reference steel material.

The chemical composition of this powder was determined by energydispersive X-ray spectroscopy (known as “EDX”) carried out by SEM, GDMS,ICP-OES and IGA; the compiled measurements are shown in FIG. 13 and FIG.14. The relative uncertainty in the measurement was 3%.

The particles of this reference powder were essentially spherical. Theirdiameter was in the range 10 μm to 100 μm with an average diameter of 30μm. Its median diameters D₁₀, D₅₀ and D₉₀, measured by lasergranulometry in accordance with the standard ISO 13320 (2009 Dec. 1edition), were as follows: D₁₀=21 μm, D₅₀=28 μm, and D₉₀=39 μm.

The apparent density, measured by the standard ASTM B-212, was 4.39g/cm³±0.01 g/cm³. The true density, measured by helium pycnometry, was7.99 g/cm³±0.03 g/cm³.

The Hall flow rate (capacity to make 50 g of powder flow through anorifice of fixed dimensions), measured in accordance with the standardASTM B213, was 16 seconds. A steel powder used in the manufacturingprocess of the invention has, for example, a Hall flow rate in the range30 seconds to 500 seconds.

The reference solid material obtained had a chemical composition asindicated in FIG. 17 as a percentage by weight in the matrix and in twodifferent metallic oxide precipitates.

Regarding its microstructure, the reference solid material had acellular structure.

The grains constituting these cells comprised a matrix into which theprecipitates had been incorporated. The corresponding structure isrepresented on the images of FIGS. 15 and 16, which show that the axialgrowth of the reference steel material produced a columnar and thereforeanisotropic structure for the grains in a plane parallel to thedirection z of additive manufacture of the material. These grains had anaverage width (D min) of 20.8 μm±2.7 μm and an average length (D max) of68.6 μm±8.3 μm, i.e. an average ratio D max/D min of 3.2±0.1.

This microstructural characteristic is illustrated by FIG. 18, whichshows that the reference steel material has a texture in the plane (110)parallel to the build direction Z resulting in a strong textureintensity equal to 5.4.

In order to compare the properties linked to the microstructure of thereference steel material with respect to the steel material of theinvention, various treatments were applied:

-   -   the reference steel material underwent a hot isostatic pressing        treatment (denoted “HIP”) identical to that of Example 4;    -   the reference steel material and the steel material of the        invention underwent a heat treatment (denoted “TT”) consisting        of a treatment, in which each unrefined build material was        maintained at a temperature of 700° C. for 1 hour (known as        “stress relieving” treatment).

At the end of these treatments, the average grain size was measured bythe intercept method for the reference steel material and the steelmaterial of the invention as obtained at the end of:

-   -   i) the additive manufacturing process (unrefined build), or    -   ii) the additive manufacturing process followed by the stress        relieving heat treatment (“TT”), or    -   iii) the additive manufacturing process followed by the hot        isostatic pressing treatment (“HIP”).

This average size was measured for the largest dimension “D max”(length) or the smallest dimension “D min” (width) of the grainsconstituting each material. The corresponding ratio D max/D min wascalculated in order to evaluate the equiaxial nature of the grains ofeach material.

The results are presented in FIG. 19, which shows that the referencesteel material (denoted “Trumpf”) underwent modifications in thegeometry of its grains after the heat treatment, but especially afterhot isostatic pressing. The distribution of the misorientation angleswas thus modified for the reference steel material.

In contrast, the microstructure of the steel material of the invention(denoted “Material”) was extremely stable, because no substantialmodifications to the geometry of the grains were observed (inparticular, the grain size remained small, namely, for example, lessthan or equal to 50 μm for L and l), which provides the steel materialof the invention with great robustness and mechanical and thermalstability.

The mechanical properties of the “Praxair” steel material of theinvention (new measures taken) and of the “Trumpf” reference steelmaterial were measured before and after having undergone the treatmentof the invention comprising a step for hot isostatic pressing (HIP). Theresulting table of FIG. 20 summarises the values obtained for theparameters Rm (maximum tensile strength, expressed in MPa), Rp0.2 (yieldstrength, expressed in MPa), A (elongation at break, as a %), both in adirection parallel (//Z)) to and perpendicular (⊥Z)) to the direction zof additive manufacture of the two materials. At the same time, thepercentage anisotropy for each of these parameters is indicated: thesmaller this percentage is, the more isotropic are the mechanicalproperties, namely that their value is homogeneous irrespective of thedirection of measurement.

The analysis of FIG. 19 and FIG. 20 shows that:

-   -   before the HIP treatment, the mechanical anisotropy (Rm, R p0.2        and A) was lower for the steel material of the invention        (Praxair) than for the reference steel material.    -   After the HIP treatment, the mechanical anisotropy was greatly        reduced for the two materials (Praxair and Trumpf). However,        only the steel material of the invention did not suffer an        increase in the average size of these grains by the phenomenon        of grain coalescence. This size remained stable and below 30 μm        despite the HIP treatment.

In conclusion, the steel material of the invention obtained after theHIP treatment of the invention has equiaxial grains, isotropicmechanical properties, a fine microstructure (the average grain size isgenerally 50 μm or less, for example an average size “D max” and/or “Dmin” in the range 10 μm to 50 μm, or even in the range 10 μm to 30 μm)and precipitates which are generally nanometric in size (generally inthe range 10 nm to 100 nm).

Clearly, the present invention is not in any way limited to theembodiments described and shown, and the person skilled in the art willbe able to combine them and use their general knowledge to make manyvariations and modifications.

1. A part composed entirely or in part of a steel material, comprisinggrains comprising a matrix into which precipitates are incorporated,wherein i) the steel material comprises, in weight percentage: 16% to20% chrome, 8% to 14% nickel, 0.001% to 0.030% carbon, 0.001% to 0.050%oxygen, 0% to 2% manganese, 0% to 3% molybdenum, 0% to 1% silicon, andiron; and ii) the precipitates comprise at least one metallic elementselected from the group consisting of a metallic element M, a metallicelement M′, and a metallic element M″ wherein each of the metallicelements M, M′ and M″ is, if present, at least one selectedindependently from the group consisting of yttrium, titanium, iron,chromium, tungsten, silicon, zirconium, thorium, magnesium, manganese,aluminium, hafnium, and molybdenum; and wherein the steel material has amicrostructure of equiaxed grains having an average grain size of from10 μm to 50 μm at a largest dimension D max and/or a smallest dimensionD min.
 2. The part according to claim 1, wherein the part has a cellularstructure or a honeycomb structure.
 3. The part according to claim 2,wherein the part has a honeycomb structure, a lattice structure or afoam structure.
 4. The part according to claim 1, wherein the grains ofthe steel material are equiaxed in a plane which is parallel to a planeof superimposed layers of a material manufactured by an additivemanufacturing process.
 5. The part according to claim 4, wherein thegrains of the steel material are additionally equiaxed in a plane whichis perpendicular to a plane of superimposed layers of a materialmanufactured by an additive manufacturing process.
 6. The part accordingto claim 5, wherein the equiaxed grains of the steel material have anaverage ratio D max/D min of the largest dimension D max to the smallestdimension D min of a grain in a range of from 1 and
 2. 7. The partaccording to claim 6, wherein the precipitates of the steel materialcomprise a metallic element M and the metallic element M is titanium,iron, chromium or mixtures thereof.
 8. The part according to claim 1,wherein the precipitates of the steel material comprise at least oneselected from the group consisting of a metal oxide, a metal carbide, ametal oxycarbide, and an intermetallic compound; each of whichcomprising at least one metallic element of the metallic elements M, M′and M″.
 9. The part according to claim 8, wherein the precipitates ofthe steel material comprise a metal oxide and the metal oxide is atleast one selected from the group consisting of: a simple oxide MO_(2-x)wherein x is in a range of from 0 to 1, a mixed oxide MM′_(y′)O_(5-x′)wherein x′ is greater than or equal to 0 but less than 5, and y′ isgreater than 0 but less than or equal to 2, and at least one mixed oxideMM′_(y′)M″_(y″)O_(5-x″) wherein x″ is greater than or equal to 0 andless than 5, y′ is greater than 0 but less than or equal to 2, and y″ isin a range of from 0 to
 2. 10. The part according to claim 9, whereinthe metal oxide comprises a simple oxide MO_(2-x) and the simple oxideMO_(2-x) is at least one selected from the group consisting of Y₂O₃,Fe₂O₃, FeO, Fe₃O₄, Cr₂O₃, TiO₂, Al₂O₃, HfO₂, SiO₂, ZrO₂, ThO₂, MgO, MnO,and MnO₂.
 11. The part according to claim 10, wherein the simple oxideMO_(2-x) is TiO₂.
 12. The part according to claim 9, wherein the metaloxide comprises a mixed oxide MM′_(y′)O_(5-x′) and the mixed oxideMM′_(y′)O_(5-x′) is at least one selected from the group consisting ofFeTiO₃, Y₂Ti₂O₇, and YTi₂O₅.
 13. The part according to claim 12, whereinthe precipitates of the steel material comprise a metal carbide and themetal carbide is at least one selected from the group consisting of: asimple carbide MC_(8-x) wherein x is in a range of from 0 to 8, and amixed carbide MM′_(y′)C_(8-x′) wherein x′ is greater than or equal to 0but less than 8 and y′ is in a range of from 0 to
 5. 14. The partaccording to claim 13, wherein the metal carbide comprises a simplecarbide MC_(8-x) and the simple carbide MC_(8-x) is at least oneselected from the group consisting of TiC, SiC, AlC₃, and CrC.
 15. Thepart according to claim 13, wherein the metal carbide comprises a mixedcarbide MM′_(y′)C_(8-x′) and the mixed carbide MM′_(y′)C_(8-x′) is(FeCr)₇C₃ or (FeCr)₂₃C₆.
 16. The part according to claim 8, wherein theprecipitates of the steel material comprise a metal oxycarbide and themetal oxycarbide comprises a metal oxide and a metal carbide wherein themetal oxide is at least one selected from the group consisting of: asimple oxide MO_(2-x) wherein x is in a range of from 0 to 1, a mixedoxide MM′_(y′)O_(5-x′) wherein x′ is greater than or equal to 0 but lessthan 5, and y′ is greater than 0 but less than or equal to 2, and atleast one mixed oxide MM′_(y′)M_(y″)O_(5-x″) wherein x″ is greater thanor equal to 0 and less than 5, y′ is greater than 0 but less than orequal to 2, and y″ is in a range of from 0 to 2, and the metal carbideis at least one selected from the group consisting of: a simple carbideMC_(8-x) wherein x is in a range of from 0 to 8, and a mixed carbideMM′_(y′) C_(8-x′) wherein x′ is greater than or equal to 0 but less than8 and y′ is in a range of from 0 to
 5. 17. The part according to claim8, wherein the precipitates of the steel material comprise anintermetallic compound and the intermetallic compound is at least oneselected from the group consisting of YFe₃, Fe₂Ti, and FeCrWTi.
 18. Thepart according to claim 1, wherein the steel material comprises 0.1% to1.5% by weight of the precipitates.
 19. The part according to claim 8,wherein the precipitates of the steel material comprise a metal carbideand have an average size of from 10 nm to 50 nm.
 20. The part accordingto claim 8, wherein the precipitates of the steel material comprise ametal oxide and/or a metal oxycarbide and have an average size of from10 nm to 100 nm.
 21. The part according to claim 1, wherein an averagedensity with which the precipitates are distributed in the matrix of thesteel material is from 2 precipitates/μm³ to 100 precipitates/μm³. 22.The part according to claim 1, wherein the steel material furthercomprises, in weight percentage, at least one of elements: 0% to 0.11%nitrogen, 0% to 0.045% phosphorus, 0% to 0.05% sulphur, 0% to 0.0300%aluminium, 0% to 2% manganese, 0% to 3% molybdenum, and 0% to 0.003%vanadium.
 23. The part according to claim 1, wherein the matrix of thesteel material comprises, in proportion by weight to a weight of thesteel material, 0 ppm to 500 ppm of the metallic element M, 0 ppm to 500ppm of the metallic element M′ and/or 0 ppm to 500 ppm of the metallicelement M″.
 24. The part according to claim 1, wherein the metallicelement M, M′ or M″ is yttrium, titanium, tungsten, zirconium, thorium,aluminium, hafnium, silicon, manganese or molybdenum.
 25. The partaccording to claim 1, wherein the steel material is of austeniticstructure.
 26. The part according to claim 25, wherein the matrix of thesteel material has a chemical composition of a 316 L or 304 L typesteel.
 27. Process A process for manufacturing the part according toclaim 1, comprising: manufacturing the part by an additive manufacturingprocess.
 28. The process according to claim 27, wherein the additivemanufacturing method is selective laser melting, selective electron beammelting, selective laser sintering, laser spraying or binder spraying.29. The process according to claim 27, wherein the process is followedby a treatment process comprising a hot isostatic pressing.
 30. Theprocess according to claim 29, wherein the hot isostatic pressingcomprises the following successive steps carried out in a chambercomprising an inert gaseous atmosphere at a pressure comprised between120 bar and 1800 bar: A. heating the steel material at a constanttemperature comprised between 600° C. and 1400° C. at a rate oftemperature increase comprised between 500° C./hour and 1000° C./hour;B. maintaining the constant temperature for a period comprised between15 minutes and 5 hours; and C. lowering the constant temperature at arate of temperature decrease comprised between 500° C./hour and 1000°C./hour to reach room temperature.
 31. The process according to claim30, wherein the inert gaseous atmosphere comprises at least one gasselected from the group consisting of argon and helium.